Advanced Process Safety Management (PSM) Compliance & Best Practices (OSHA 1910.119 & CCPS)

This advanced course focuses on the critical components of Process Safety Management (PSM), emphasizing compliance with OSHA 1910.119 and CCPS guidelines. It provides an in-depth understanding of PSM regulations and industry best practices, designed to help organizations reduce process risks, protect employees, and prevent accidents. The course also covers the implementation of an effective PSM program and the integration of hazard analysis, risk management, and operational safety practices within an organization’s culture. Participants will leave with actionable knowledge to lead and manage PSM efforts, ensuring compliance and improving safety performance.

Assessment and Certification:

Knowledge Assessment: Through case study analysis and group exercises.
Final Project: Completion of a PSM audit or hazard analysis for a complex process scenario.
Certificate: Participants will receive a course completion certificate upon successfully finishing the course, which demonstrating expertise in PSM compliance and best practices.

Audience

This course is intended for professionals working in risk management, process safety, operations, and safety leadership roles, including:

Process Safety Managers and Engineers
Health, Safety, and Environmental (HSE) Managers
Operations Managers
Risk Managers
Regulatory Compliance Officers
Safety Consultants
Engineers and Supervisors working in high-risk industries (Chemical, Oil & Gas, Pharmaceuticals, Manufacturing)

Course objectives

By the end of this course, participants will:

Gain comprehensive knowledge of OSHA 1910.119 and CCPS PSM standards and how they apply to high-risk industries.
Understand PSM compliance requirements and best practices for preventing catastrophic accidents.
Learn how to develop, implement, and sustain an effective PSM program in alignment with regulatory requirements and industry best practices.
Conduct hazard analyses (e.g., HAZOP, What-If, LOPA) and develop risk management
Build a PSM culture within an organization by addressing leadership, communication, and training needs.
Learn about the Management of Change (MOC) process, incident investigation, and emergency planning.
Use case studies to understand common compliance failures and learn how to address them.
Develop strategies for continuous improvement in PSM compliance and overall safety performance.

Course contents

Day 1: Introduction to PSM Compliance & Regulatory Framework

Pretest
Overview of PSM in OSHA 1910.119 and CCPS
- Key principles of Process Safety Management (PSM)
- Regulatory overview: OSHA 1910.119 and CCPS Guidelines
- Roles and responsibilities of stakeholders in PSM implementation
- Key definitions: Process Safety, Major Accident Hazards, High-Risk Processes
- PRA (Process Risk Assessment) and its role in PSM
Understanding the 14 Elements of PSM (OSHA 1910.119)
- Process Safety Information (PSI)
- Process Hazard Analysis (PHA) and Risk Assessment
- Operating Procedures and Safe Work Practices
Case Study: A review of industry PSM incidents and compliance failures

Day 2: Hazard Analysis and Risk Assessment Techniques

HAZOP (Hazard and Operability Study)
- Key principles of HAZOP for hazard identification
- Structuring a HAZOP study and conducting hazard analysis
- Mitigation measures and designing effective barriers
What-If and LOPA (Layer of Protection Analysis)
- Applying What-If techniques for process safety analysis
- Understanding the LOPA framework for risk assessment
- Analyzing and assessing the adequacy of protective layers
Practical Exercise: Conducting a HAZOP session for a sample process

Day 3: Management of Change (MOC), Operating Procedures, and Compliance Audits

Management of Change (MOC)
- Understanding the MOC process in PSM compliance
- Ensuring the MOC process is aligned with OSHA and CCPS standards
- Integrating MOC into daily operations and ensuring safety during changes
- Documentation and risk analysis during change
Operating Procedures and Safe Work Practices
- Writing and implementing safe operating procedures
- Procedures for startup, shutdown, and emergency operations
- Training and communication on safe work practices
PSM Compliance Audits
- Performing PSM audits to assess compliance with OSHA 1910.119 and CCPS
- Developing audit checklists for different PSM elements
- Audit findings and implementing corrective actions
Practical Exercise: Simulated MOC and PSM audit process

Day 4: Incident Investigation, Emergency Planning, and Response

Incident Investigation
- Best practices for investigating PSM-related incidents
- Root cause analysis (RCA) and using Bowtie Analysis for incident investigation
- Writing investigation reports and implementing corrective actions
- CCPS Guidelines for incident investigation and learning from failures
Emergency Planning and Response
- Developing and implementing emergency response plans for major accidents
- Coordination with external agencies and first responders
- Business continuity and disaster recovery plans
Case Study: Lessons from real-life incidents in PSM

Day 5: Building PSM Culture and Continuous Improvement

Building a PSM Culture
- Role of leadership in fostering a strong PSM culture
- Communication strategies for safety and risk management
- Engaging the workforce in PSM ownership and accountability
- Role of training and awareness in maintaining PSM culture
PSM Program Evaluation and Continuous Improvement
- Developing PSM performance indicators and metrics
- Continuous improvement tools: PDCA (Plan-Do-Check-Act) cycle, Kaizen principles
- Conducting PSM reviews and updating systems as per new regulations
- Long-term sustainability and resilience of PSM programs
Course Wrap-Up: Review of Key Takeaways, Q&A, and Final Assessment

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